Goodman GMEC96 Guide
Service and Troubleshooting
®®
Copyright © 2014-2020 Goodman Manufacturing Company, L.P.
RS6612013r10
June 2020
®
is a registered trademark of Maytag Corporation or its related companies and is used under license.
All rights reserved.
TABLE OF CONTENTS
IMPORTANT INFORMATION............................................ 2
PRODUCT IDENTIFICATION ........................................... 4
SYSTEM OPERATION...................................................... 7
SCHEDULED MAINTENANCE ....................................... 42
SERVICING..................................................................... 46
CHECKING VOLTAGE .............................................. 47
CHECKING WIRING .................................................. 47
CHECKNG THERMOSTAT, WIRING ........................ 47
HEATING ANTICIPATOR........................................... 47
CHECKING TRANSFORMER AND CONTROL
CIRCUIT...................................................................... 47
CHECKING AIR CIRCULATOR BLOWER MOTOR 48
CHECKING DUCT STATIC........................................ 48
CHECKING TEMPERATURE RISE .......................... 49
CHECKING PRIMARY LIMIT CONTROL................. 49
CHECKING AUXILIARY LIMIT CONTROL............... 50
CHECKING FLAME ROLLOUT CONTROL ............. 51
INDUCED DRAFT BLOWER MOTOR ...................... 52
CECKING GAS VALVE (REDUNDANT) ................... 52
CHECKING MAIN BURNERS ................................... 52
CHECKING ORIFICES .............................................. 52
CHECKING GAS PRESSURE .................................. 53
CHECKING HOT SURFACE IGNITOR..................... 55
CHECKING FOR FLASHBACK................................. 55
CHECKING PRESSURE SWITCH............................ 55
HIGH ALTITUDE APPLICATION ............................... 56
CHECKING FOR DELAYED IGNITION.................... 56
CHECKING INTERGRATED IGNITION CONTROL
BOARDS ..................................................................... 56
CHECKING FLAME SENSOR................................... 57
TROUBLESHOOTING CHART ....................................... 58
WIRING DIAGRAMS....................................................... 61
Pride and workmanship go into every product to provide
our customers with quality products. It is possible, however,
that during its lifetime a product may require service.
technician who is familiar with the safety procedures
required in the repair and who is equipped with the proper
tools, parts, testing instruments and the appropriate service
manual.
Cancer and Reproductive Harm -
www.P65Warnings.ca.gov
0140M00517-A
IMPORTANT INFORMATION
2
Pride and workmanship go into every product to provide our
customers with quality products. It is possible, however, that
during its lifetime a product may require service. Products
is familiar with the safety procedures required in the repair
and who is equipped with the proper tools, parts, testing in-
struments and the appropriate service manual.
OUTSIDE THE U.S., .
(Not a technical assistance line for dealers.) Your telephone company will bill you for the call.
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IMPORTANT INFORMATION
3
B10259-216
CO can cause serious illness including permanent brain
damage or death.
Advertencia especial para la instalación de calentadores ó manejadoras
de aire en áreas cerradas como estacionamientos ó cuartos de servicio.
B10259-216
El monóxido de carbono puede causar enfermedades severas
como daño cerebral permanente ó muerte.
Las emisiones de monóxido de carbono pueden circular a través
del aparato cuando se opera en cualquier modo.
B10259-216
RISQUE D'EMPOISONNEMENT AU MONOXYDE DE CARBONE
Cette ventilation est nécessaire pour éviter le danger d'intoxication
au CO pouvant survenir si un appareil produisant du monoxyde
de carbone continue de fonctionner au sein de la zone confinée.
PRODUCT IDENTIFICATION
4
Please use these numbers when requesting service or parts information.
* M E C 96 60 3 B N A A
14 11 14
Brand Minor Revision
A - Amana
®
Brand A - Initial Release
G - Goodman
®
Brand
B - 1st Revision
Configuration Major Revision
M - Upflow / Horizontal A - Initial Release
C - Downflow / Horizontal B - 1st Revision
Motor NOx
V - Variable Speed ECM / ComfortNet N - Low NOx
E - Multi-Speed ECM
S - Single Speed Cabinet Width
A - 14"
Gas Valve B - 17.5"
M - Modulating C - 21"
C - 2 Stage D - 24.5"
S - Single Stage
Maximum CFM
AFUE 2 - 800 CFM
96 - 96% AFUE 3 - 1200 CFM
92 - 92% AFUE 4 - 1600 CFM
5 - 2000 CFM
MBTU/h
040 - 40,000 BTU/h
060 - 60,000 BTU/h
PRODUCT IDENTIFICATION
5
MODEL # MFG. # DESCRIPTION
AMEC960402BNAA
AMEC960603BNAA
AMEC960803BNAA
AMEC961004CNAA
AMEC961205DNAA
Amana ®Brand 96% Two Stage Heating / Two Stage Cooling Gas Furnace, Up
flow/Horizontal Left and Right, 34.5" tall, Induced Draft, Nidec multi-speed ECMmotor.
Stainless Steel tubular heat exchanger. 115 volt silicon nitride igniter. Left or right gas.
AMEC960302BNAB
AMEC960402BNAB
AMEC960603BNAB
AMEC960803BNAB
AMEC961004CNAB
AMEC961205DNAB
AMEC960804CNAB
AMEC961005CNAB
Amana ®Brand 96% Two Stage Heating / Two Stage Cooling Gas Furnace, Up
flow/Horizontal Left and Right, 34.5" tall, Induced Draft, Nidec multi-speed ECMmotor.
Stainless Steel tubular heat exchanger. 115 volt silicon nitride igniter. Left or right gas.
AMEC960303ANAA
AMEC960403ANAA
AMEC960603ANAA
AMEC960302BNAC
AMEC960402BNAC
AMEC960603BNAC
AMEC960803BNAC
AMEC960804CNAC
AMEC961004CNAC
AMEC960603BNBA
AMEC961005CNAC
AMEC961205DNAC
Amana ®Brand 96% Two Stage Heating / Two Stage Cooling Gas Furnace, Up
flow/Horizontal Left and Right, 34.5" tall, Induced Draft, Nidec multi-speed ECMmotor.
Stainless Steel tubular heat exchanger. 115 volt silicon nitride igniter. Left or right gas.
GMEC960402BNAA
GMEC960603BNAA
GMEC960803BNAA
GMEC961004CNAA
GMEC961205DNAA
Goodman®Brand 96% Two Stage Heating / Two Stage Cooling Gas Furnace, Up
flow/Horizontal Left and Right, 34.5" tall, Induced Draft, Nidec multi-speed ECMmotor.
Stainless Steel tubular heat exchanger. 115 volt silicon nitride igniter. Left or right gas.
GMEC960302BNAB
GMEC960402BNAB
GMEC960603BNAB
GMEC960803BNAB
GMEC961004CNAB
GMEC961205DNAB
GMEC960804CNAB
GMEC961005CNAB
Goodman®Brand 96% Two Stage Heating / Two Stage Cooling Gas Furnace, Up
flow/Horizontal Left and Right, 34.5" tall, Induced Draft, Nidec multi-speed ECMmotor.
Stainless Steel tubular heat exchanger. 115 volt silicon nitride igniter. Left or right gas.
GMEC960303ANAA
GMEC960403ANAA
GMEC960603ANAA
GMEC960302BNAC
GMEC960402BNAC
GMEC960603BNAC
GMEC960803BNAC
GMEC960804CNAC
GMEC961004CNAC
GMEC961005CNAC
GMEC960603BNBA
GMEC961205DNAC
Goodman®Brand 96% Two Stage Heating / Two Stage Cooling Gas Furnace, Up
flow/Horizontal Left and Right, 34.5" tall, Induced Draft, Nidec multi-speed ECMmotor.
Stainless Steel tubular heat exchanger. 115 volt silicon nitride igniter. Left or right gas.
AMEC96
GMEC96
PRODUCT IDENTIFICATION
6
MODEL # MFG. # DESCRIPTION
ACEC96
ACEC960403BNAA
ACEC960603BNAA
ACEC960803BNAA
ACEC961005BNAA
Amana
®
Brand 96% Two Stage Heating / Two Stage Cooling Gas Furnace, Counter
flow/Horizontal Left and Right, 34.5" tall, Induced Draft, Nidec multi-speed ECM motor.
Stainless Steel tubular heat exchanger. 115 volt silicon nitride igniter. Left or right gas.
PCBBF139 Control board which gives installer multiple CFM choices for constant fan
mode.
GCEC96
GCEC960403BNAA
GCEC960603BNAA
GCEC960803BNAA
GCEC961005BNAA
Goodman
®
Brand 96% Two Stage Heating / Two Stage Cooling Gas Furnace, Counter
flow/Horizontal Left and Right, 34.5" tall, Induced Draft, Nidec multi-speed ECMmotor.
Aluminized Steel tubular heat exchanger. 115 volt silicon nitride igniter. Left or right
gas. PCBBF139 Control board which gives installer multiple CFM choices for constant
fan mode.
SYSTEM OPERATION
7
This is a Category lV furnace. This furnace uses a pressurized
venting system and must be installed per National and local
codes requirements and the installation manual that was
shipped with the furnace.
The *MEC96 34.5” furnace is one of the products in our newly
redesigned line of shorter chassis furnaces. It is available
installation.
*MEC960303ANA *CEC960402BNAA
*MEC960403ANA *CEC960603BNAA
*MEC960603ANA *CEC960803BNAA
*MEC960302BNA *CEC961005CNAA
*MEC960402BNA Suitable for counter
*MEC960603BNB installation.
*MEC960803BNA
*MEC960804CNA
*MEC961004CNA
*MEC961005CNA
*MEC961205DNA
Please adhere to the following warnings and cautions when
installing, adjusting, altering, servicing, or operating the
furnace.
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Discharge body’s static electricity before touching
components.
Use the following precautions during furnace installation
and servicing to protect the integrated control module from
damage. By putting the furnace, the control, and the person
at the same electrostatic potential, these steps will help
avoid exposing the integrated control module to electrostatic
discharge. This procedure is applicable to both installed and
uninstalled (ungrounded) furnaces.
1. Disconnect all power to the furnace. Do not touch the
integrated control module or any wire connected to the
control prior to discharging your body’s electrostatic
charge to ground.
2. Firmly touch a clean, unpainted, metal surface of the
furnace near the control. Any tools held in a person’s
hand during grounding will be discharged.
3. Service integrated control module or connecting wiring
following the discharge process in Step 2. Use caution
not to recharge your body with static electricity; (i.e., do
objects, etc.). If you come in contact with an ungrounded
object, repeat Step 2 before touching control or wires.
4. Discharge any static electricity from your body to ground
before removing a new control from its container. Follow
Steps 1 through 3 if installing the control on a furnace.
Return any old or new controls to their containers before
touching any ungrounded object.
This product is designed for use as a residential home gas
furnace. It is
trailer, or recreational vehicle applications.
This furnace can be used in the following non-industrial commercial
applications:
In such
applications, the furnace must be installed with the installation
instructions.
appropriate for use with natural or propane gas. (If
using propane gas, a propane conversion kit is required).
optional and the furnace can be vented as a:
• Non-direct vent (single pipe) central forced air furnace in
which combustion air is taken from the installation area
or from air ducted from the outside or,
• Direct vent (dual pipe) central forced air furnace in
which all combustion air supplied directly to the furnace
burners through a special air intake system outlined in
this manual and the installation instructions.
To ensure proper installation, operation and servicing,
thoroughly read the installation and service manuals
application of this product.
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SYSTEM OPERATION
8
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To ensure proper furnace operation, install, operate, maintain
and service the furnace in accordance with the installation,
operation and service instructions, all local building codes
and ordinances. In their absence, follow the latest edition of
the National Fuel Gas Code (NFPA 54/ANSI Z223.1), and/or
CAN/CGA B149 Installation Codes, local plumbing or waste
water codes, and other applicable codes.
A copy of the National Fuel Gas Code (NFPA 54/ANSI Z223.1)
can be obtained from any of the following:
25 West 43rd Street, 4th Floor
New York, NY 10036
1 Batterymarch Park
Quincy, MA 02169-7471
8501 East Pleasant Valley
Cleveland, OH 44131
A copy of the CAN/CGA B149 Installation Codes can be
obtained from:
178 Rexdale Boulevard
Etobicoke, Ontario, Canada M9W, 1R3
The rated heating capacity of the furnace should be greater
than or equal to the total heat loss of the area to be heated.
The total heat loss should be calculated by an approved
method or in accordance with “ASHRAE Guide” or “Manual
J-Load Calculations” published by the Air Conditioning
Contractors of America.
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Follow the instructions listed below when selecting a
furnace location. Refer also to the guidelines provided in the
Combustion and Ventilation Air Requirements section in this
manual or the installation instructions for details.
• Centrally locate the furnace with respect to the proposed
or existing air distribution system.
• Ensure the temperature of the return air entering the
furnace is between 55°F and 100°F when the furnace
is heating.
• If the furnace is installed in an application where the
typical operating sound level of a furnace is deemed
objectionable, an optional sound reduction kit is
available. Consult your local distributor for more details.
• Provide provisions for venting combustion products
outdoors through a proper venting system. Special
and combustion air intake pipe when applicable.
• Refer to the Vent/Flue Pipe and
Combustion Air Pipe -Termination Locations section in
this manual or the installation instructions for appropriate
termination locations. Also for 90% furnaces, refer to the
Vent/Flue Pipe and Combustion Air Pipe -Termination
Locations section in this manual or the installation
instructions to determine if the piping system from
furnace to termination can be accomplished within the
guidelines given
•
can be a limiting factor in the location of the furnace.
• Locate the 90% furnace so that the condensate can be
piped at a downward slope away from the furnace to
the drain. Do not locate the furnace or its condensate
drainage system in any area subject to below freezing
temperatures without proper freeze protection. Refer
to the Condensate Drain Lines and Trap section in this
manual or the installation instructions for further details.
•
condensate drainage. If the floor becomes wet or
concrete base sized approximately 1-1/2” larger
than the base of the furnace. Refer to the Horizontal
Applications and Considerations section in this manual
or the installation instructions for leveling of horizontal
furnaces.
•
directly on carpeting, or any other combustible material.
The only combustible material allowed is wood.
• Exposure to contaminated combustion air will result in
safety and performance-related problems. Do not install
the furnace where the combustion air is exposed to the
following substances:
chlorinated waxes or cleaners
chlorine-based swimming pool chemicals
water softening chemicals
deicing salts or chemicals
carbon tetrachloride
halogen type refrigerants
cleaning solutions (such as perchloroethylene)
printing inks
paint removers
varnishes
hydrochloric acid
SYSTEM OPERATION
9
cements and glues
antistatic fabric softeners for clothes dryers
and masonry acid washing materials
• Isolate a non-direct vent furnace if it is installed near
an area frequently contaminated by any of the above
substances. This protects the non-direct vent furnace
from airborne contaminants. To ensure that the enclosed
non-direct vent furnace has an adequate supply of
combustion air, vent from a nearby uncontaminated
room or from outdoors. Refer to the Combustion and
Ventilation Air Requirements section in this manual or
the installation instructions for details.
• If the furnace is used in connection with a cooling unit,
install the furnace upstream or in parallel with the cooling
unit coil. Premature heat exchanger failure will result
if the cooling unit coil is placed in the return air of the
furnace.
• If the furnace is installed in a residential garage, position
the furnace so that the burners and ignition source are
Protect the furnace from physical damage by vehicles.
• If the furnace is installed horizontally, the furnace access
into the heat exchanger. Do not install the unit with the
access doors on the “up/top” or “down/bottom” side of
the furnace.
•
must be downstream on the supply (positive) side of
the furnace heat exchanger.
• Counterow Installation over a noncombustible oor.
Before setting the furnace over the plenum opening,
ensure the surface around the opening is smooth and
level. A tight seal should be made between the furnace
compound or cement grout.
• Counterow Installation over a combustible oor. If
applicable for your model for details). A special
unit installations over any combustible material including
wood. Refer to sub-base instructions for installation
details. Follow the instructions with the sub-base for
proper installation. Do not install the furnace directly
on carpeting, tile, or other combustible material other
• ( The sub-base will not be required if an air
conditioning coil is installed between the supply air
POSITION* SIDES REAR FRONT BOTTOM FLUE TOP
Upflo w 0" 0" 1" C0" 1"
Horizontal 6" 0" 1" C0" 6"
*M EC96 M INIM UM CLEARANCES TO COMBUSTIBLE MATERIALS
POSITION* SIDES REAR FRONT BOTTOM FLUE TOP
Counterflow 0" 0" 1" NC 0"
Horizontal 6" 0" 1" C0" 6"
*CEC96 M INIM UM CLEARANCES TO COMBUSTIBLE MATERIALS
•
•
• For servicing or cleaning, a 24” front clearance is recommended.
•
clearances than the minimum clearances listed above.
• In all cases, accessibility clearance must take precedence over from
the enclosure where accessibility clearances are greater.
• Approved for line contact in the horizontal position.
Installations must adhere to the clearances to combustible
minimum clearance information for this furnace is provided
on the unit’s clearance label. These clearances must be
minimum clearances to combustible materials. Clearances
must also accommodate an installation’s gas, electrical,
and drain trap and drain line connections. If the alternate
a 90% furnace, additional clearances must be provided to
accommodate these connections. Refer to Vent Flue Pipe and
Combustion Air Pipe section in this manual or the installation
instructions for details. In addition to the required
clearances to combustible materials, a minimum of 24 inches
service clearance must be available in front of the unit.
utility room) must have two ventilation openings with a total
minimum free area of 0.25 square inches per 1,000 BTU/hr of
furnace input rating. One of the ventilation openings must be
within 12 inches of the top; the other opening must be within
construction, the clearance between the door and door frame
is usually adequate to satisfy this ventilation requirement.
SYSTEM OPERATION
10
If suspending the furnace from rafters or joist, use 3/8”
threaded rod and 2”x2”x1/8” angle iron as shown in the
a concrete pad. Never install the furnace on the ground or
allow it to be exposed to water. The length of rod will depend
on the application and the clearances necessary.
TILT OUTWARD TO ALLOW FOR
DOOR AND CIRCULATOR BLOWER
REMOVAL.
3/8" DIAMETER
THREADED ROD
(6 PLACES)
PROVIDE 8" MINIMUM CLEARANCE BETWEEN
CENTER ROD AND FURNACE CABINET
TO ALLOW FOR CIRCULATOR BLOWER REMOVAL.
ASSURE FURNACE IS LEVEL FROM
END TO END.
ON 90% FURNACES MAKE SURE
THE UNIT HAS A SLIGHT
FORWARD TILT WITH THE FRONT
OF THE FURNACE 0"-3/4"
BELOW THE BACK OF THE FURNACE.
POSITION AS CLOSE AS POSSIBLE
TO BLOWER DECK TO ALLOW FOR
CIRCULATOR BLOWER REMOVAL.
2"
X
2"
X
1/8"
ANGLE IRON
(3 PLACES)
HOLD DOWN
NUTS
SUPPORT
NUTS
CONDENSATE
DRAIN
GAS PIPING
ALTERNATE
GAS PIPING
When an existing furnace is removed from a venting
system serving other appliances, the venting system may be
too large to properly vent the remaining attached appliances.
The following vent testing procedure is reproduced from
the
The following steps shall be followed with each appliance connected
to the venting system placed in operation, while any other appliances
connected to the venting system are not in operation:
a. Seal any unused openings in the venting system;
b. Inspect the venting system for proper size and horizontal pitch,
as required by the National Fuel Gas Code, ANSI Z223.1
or the CSA B149 Installation Codes and these instructions.
Determine that there is no blockage or restriction, leakage,
condition;
c. In so far as practical, close all building doors and windows
and all doors between the space in which the appliance(s)
connected to the venting system are located and other spaces
of the building. Turn on clothes dryers and any appliance not
connected to the venting system. Turn on any exhaust fans,
such as range hoods and
bathroom exhausts, so they shall operate at maximum
dampers;
d. Follow the lighting instructions. Place the appliance being
inspected in operation. Adjust thermostat so appliance shall
operate continuously;
e. Test for draft hood equipped spillage at the draft hood relief
opening after 5 minutes of main burner operation. Use the
f. After it has been determined that each appliance connected
to the venting system properly vents when tested as outlined
and any other gas burning appliance to their previous
conditions of use;
g. If improper venting is observed during any of the above tests,
the common venting system must be corrected.
Corrections must be in accordance with the latest edition of
the National Fuel Gas Code NFPA 54/ANSI Z223.1 and/or
CSA B149 Installation Codes.
If resizing is required on any portion of the venting system,
use the appropriate table in Appendix G in the latest edition of
the National Fuel Gas Code ANSI Z223.1 and/or CSA B149
Installation Codes.
A two stage heat/cool thermostat is recommended. A single
stage heating thermostat may be used. It is recommended
that a high quality thermostat with a “C” terminal is used to
operate the furnace.
T
In an area having good air circulation, locate the thermostat
the following:
• Drafts, or dead spots behind doors, in corners, or under
cabinets.
• Hot or cold air from registers.
• Radiant heat from the sun.
•
•
• Concealed hot or cold water pipes, or chimneys.
• Unconditioned areas behind the thermostat and
dehumidistat, such as an outside wall.
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Improved construction and additional insulation in buildings
around doors and windows. These changes have helped in
reducing heating/cooling costs but have created a problem
other fuel burning appliances. Appliances that pull air out
increase the problem by starving appliances for air.
When the furnace is installed as a direct ven (2-pipe) furnace,
no special provisions for air for combustion are required.
However, if this furnace is to be installed in the same space
with other gas appliances, such as a water heater, ensure
there is an adequate supply of combustion and ventilation
SYSTEM OPERATION
11
air for the other appliances. Refer to the latest edition of the
National Fuel Gas Code NFPA 54/ANSI Z223.1 (Section
9.3), or CAN/CGA B149 Installation Codes (Sections 7.2,
7.3, or 7.4), or applicable provisions of the local building
codes for determining the combustion air requirements for
the appliances.
Most homes will require outside air be supplied to the furnace
area by means of ventilation grilles or ducts connecting
directly to the outdoors or spaces open to the outdoors such
as attics or crawl spaces.
The following information on air for combustion and ventilation
is reproduced from the
for appliances installed in buildings shall be obtained by application
of one of the methods covered in 9.3.2 through 9.3.6. Where the
requirements of 9.3.2 are not met, outdoor air shall be introduced in
accordance with methods covered in 9.3.3 through 9.3.6.
Exception No. 1: This provision shall not apply to direct vent ap-
pliances.
Appliances of other than natural draft design and other than
Category 1 vented appliances shall be provided with combustion,
ventilation, and dilution air in accordance with the appliance man-
ufacturer’s instructions.
Appliances shall be located so as not to interfere with proper
circulation of combustion, ventilation, and dilution air.
Where used, a draft hood or a barometric draft regulator shall
be installed in the same room or enclosure as the appliance served
regulator and the combustion air supply.
Makeup air requirements for the operation of exhaust fans,
be considered in determining the adequacy of a space to provide
combustion air requirements.
The required volume of indoor air
shall be determined in accordance with the method in 9.3.2.1 or
less than 0.40 ACH, the method in 9.3.2.2 shall be used. The total
required volume shall be the sum of the required volume calculated
for all appliances located within the space. Rooms communicating
directly with the space in which the appliances are installed through
openings not furnished with doors, and through combustion air open-
ings sized and located in accordance with 9.3.2.3, are considered
a part of the required volume.
The minimum required volume shall be
50 ft 3per 1,000/Btu/hour (4.8m3/kW).
-
tration rate of a structure is known, the minimum required volume
shall be determined as follows:
(1) For appliances other than fan-assisted, calculate using the
following equation:
21 ft3I other
Required Volume other > ________ _________
ACH 1000 Btu/hr
(2) For fan-assisted appliances, calculate using the following equa-
tion:
15 ft3I fan
Required Volume fan > ________ _________
ACH 1000 Btu/hr
where:
I other = all appliances other than fan-assisted input in Btu per
hour
I fan = fan-assisted appliances input in Btu per hour
ACH = air change per hour (percent of volume of space ex-
changed per hour, expressed as a decimal)
0.60 ACH shall not be used in the equations in 9.3.2.2(1) and
9.3.2.2(2).
Openings used to
connect indoor spaces shall be sized and located in accordance
with the following:
(1)* Combining spaces on the same story. Each opening shall have
a minimum free area of 1 in.2/1000Btu/hr (2200 mm2/kW) of the
total input rating of all appliances in the space but not less than
100 in.2(0.60m2). One opening shall commence within 12 in.
(300 mm) of the top, and one opening shall commence within
12 in. (300 mm) of the bottom, of the enclosure [see Figure
A.9.3.2.3(1)]. The minimum dimension of air openings shall be
not less than 3 in. (80 mm).
Furnace
Water
Heater
Opening
Chimney or Gas Vent
Opening
(2) Combining spaces in dierent stories.The volumes of spaces in
where such spaces are connected by one or more openings in
2/1000
Btu/hr (4400 mm2/kW) of total input rating of all appliances.
Outdoor combustion air shall be
provided through opening(s) to the outdoors in accordance with
the methods in 9.3.3.1 or 9.3.3.2. The minimum dimension of air
openings shall not be less than 3 in. (80 mm).
Two permanent open-
ings, one commencing within 12 in. (300 mm) of the top and one
commencing within 12 in. (300 mm) of the bottom, of the enclosure
shall be provided.
SYSTEM OPERATION
12
The openings shall communicate directly, or by ducts, with the
outdoors or spaces that freely communicate with the outdoors, as
follows:
(1)* Where directly communicating with the outdoors or where com-
municating to the outdoors through vertical ducts, each opening
shall have a minimum free area of 1 in.2/4000 Btu/hr (550 min2/
kW) of total input rating of all appliances in the enclosure. [See
Figure A.9.3.3.1(1)(a) and Figure A.9.3.3.1(1)(b).]
Furnace
Water
Heater
Outlet Air
Chimney or Gas Vent
Inlet Air
Ventilation louvers for
unheated crawl space
Alternate
air inlet
Ventilation louvers
(each end of attic)
Furnace
Water
Heater
Outlet Air
Chimney or Gas Vent
Inlet air duct
[ends 1 ft (300 mm)
above floor]
Ventilation louvers
(each end of attic)
(2)* Where communicating with the outdoors through horizontal
ducts, each opening shall have a minimum free area of 1
in.2/2000 Btu/hr (1100 min2/kW) of total input rating of all appli-
ances in the enclosure. [See Figure A.9.3.3.1(2).]
Furnace
Water
Heater
Chimney or Gas Vent
Outlet air duct
Inlet air duct
One permanent open-
ings, commencing within 12 in. (300 mm) of the top of the enclosure,
shall be provided. The appliance shall have clearances of at least
1 in. (25 mm) from the sides and back and 6 in. (150 mm) from the
front of the appliance. The opening shall directly communicate with
the outdoors or shall communicate through a vertical or horizontal
duct to the outdoors or spaces that freely communicate with the
outdoors (see Figure A.9.3.3.2) and shall have a minimum free area
of the following:
(1) 1 in.2/3000 Btu/hr (700 mm2per kW) of the total input rating of
all appliances located in the enclosure, and
(2) Not less than the sum of the areas of all vent connectors in the
space.
Furnace
Water
Heater
Opening
Chimney or Gas Vent
Alternate
Opening
Location
The use
of a combination of indoor and outdoor combustion air shall be in
accordance with (1) through (3) (see example calculation in Annex J]:
(1) Indoor Openings: Where used, openings connecting the interior
spaces shall comply with 9.3.2.3.
(2) Outdoor Opening(s) Location. Outdoor opening(s) shall be
located in accordance with 9.3.3.
(3) Outdoor Opening(s) Size. The outdoor opening(s) size shall be
calculated in accordance with the following:
(a) The ratio of the interior spaces shall be the available vol-
ume of all communicating spaces divided by the required
volume.
(b) The outdoor size reduction factor shall be 1 minus the ratio
of interior spaces.
(c) The minimum size of outdoor opening(s) shall be the full
size of outdoor opening(s) calculated in accordance with
9.3.3, multiplied by the reduction factor. The minimum
dimension of air openings shall not be less than 3 in. (80
mm).
Engineered combustion air instal-
lations shall provide an adequate supply of combustion, ventilation,
and dilution air and shall be approved by the authority having
jurisdiction.
Where all combustion
air is provided by a mechanical air supply system, the combustion
air shall be supplied form outdoors at the minimum rate of 0.35 ft3/
min per 1000 Btu/hr (0.034 m3/min per kW) for all appliances located
within the space.
Where exhaust fans are installed, additional air shall be
provided to replace the exhausted air.
SYSTEM OPERATION
13
Each of the appliances served shall be interlocked to the
mechanical air supply system to prevent main burner operation
where the mechanical air supply system is not in operation.
Where combustion air is provided by the building’s me-
combustion air rate in addition to the required ventilation air.
The required size of openings for
combustion, ventilation, and dilution air shall be based on the net
free area of each opening. Where the free area through a design
of louver or grille or screen is known, it shall be used in calculating
the louver and grille design and free area are not known, it shall be
assumed that wood louvers will have 25 percent free area, and metal
louvers and grilles will have 75 percent free area. Nonmotorized
Screens shall not be smaller
than 1/4 in. mesh.
Motorized louvers shall be interlocked
with the appliance so they are proven in the full open position prior
to main burner ignition and during main burner operation. Means
shall be provided to prevent the main burner form igniting should the
louver fail to open during burner startup and to shut down the main
burner if the louvers close during burner operation.
Combustion air ducts shall comply
with 9.3.8.1 through 9.3.8.8.
Ducts shall be constructed of galvanized steel or a material
having equivalent corrosion resistance, strength, and rigidity.
Exception: Within dwellings units, unobstructed stud and joist spaces
shall not be prohibited from conveying combustion air, provided that
not more than one reblock is removed.
Ducts shall terminate in an unobstructed space, allowing
free movement of combustion air to the appliances.
Ducts shall serve a single space.
Ducts shall not serve both upper and lower combustion
air openings where both such openings are used. The separation
between ducts servicing upper and lower combustion air openings
shall be maintained to the source of combustion air.
Ducts shall not be screened where terminating in an attic
space.
Horizontal upper combustion air ducts shall not slope down-
ward toward the source of combustion air.
The remaining space surrounding a chimney liner, gas vent,
special gas vent, or plastic piping installed within a masonry, metal,
or factory built chimney shall not be used to supply combustion air.
Exception: Direct vent appliances designed for installation in a
solid fuel-burning replace where installed in accordance with the
manufacture’s installation instructions.
Combustion air intake openings located on the exterior of
the building shall have the lowest side of the combustion air intake
openings located at least 12 in. (300 mm) vertically from the ad-
joining grade level.
left or right side down. *CEC96 models may be installed down
any furnace on its back.
Horizontal applications, in particular, may dictate many of
The basic application of this furnace as a horizontal furnace
1. Horizontal installations require 5.5” under the furnace to
accommodate the drain trap.
2. Horizontal furnaces must be installed with ¾” slope from
of the furnace.
When installing horizontally with the left side down, there
are two options for connecting the vent pipe to the furnace.
on the original top (now the end) of the furnace
2. The internal vent pipe and elbow may be removed from
the furnace to permit the vent to exit the top (original side)
of the furnace. If this option is used, an RF000142 Vent-
Drain coupling must be used to keep condensate from
collecting in the inducer assembly
Refer to the following instructions and illustration.
Insert flange. Cut 2 ½” long.
R 000142F
Figure 9
SYSTEM OPERATION
14
TR
2. Remove the internal elbow and vent pipe
4. Remove cabinet plug adjacent to inducer outlet and install
an original cabinet vent hole.
5. Install RF000142 coupling on inducer outlet.
with clamps.
In horizontal applications the condensate drain trap is secured
to the furnace side panel, suspending it below the furnace.
A minimum clearance of 5.5” below the furnace must be
provided for the drain trap. Additionally, the appropriate
downward piping slope must be maintained from the drain
trap to the drain location. Refer to Condensate Drain Trap and
Lines section in this manual or the installation instructions for
further details. If the drain trap and drain line will be exposed
to temperatures near or below freezing, adequate measures
must be taken to prevent condensate from freezing.
The use of insulation and/or heat tape is recommended.
Failure to provide proper condensate drainage can result in
property damage.
Leveling ensures proper condensate drainage from the heat
drainage, the furnace must be level lengthwise from end to
end. The furnace should also be level from back to front or
have a slight tilt with the access doors downhill (approximately
3/4”) from the back panel. The slight tilt allows the heat
exchanger condensate, generated in the recuperator coil, to
AIR
DISCHARGE
Bottom
Return
Duct
Connection
Side
Return
Duct
Connection
Side
Return
Duct
Connection
Bottom
Return
Duct
Connection
Bottom
Return
Duct
AIR
DISCHARGE
The furnaces have provisions allowing for electrical and
gas line connections through either side panel. In horizontal
applications the connections can be made either through the
“top” or “bottom” of the furnace.
A drain pan must be provided if the furnace is installed above
a conditioned area. The drain pan must cover the entire area
under the furnace (and air conditioning coil if applicable).
If the drain trap and drain line will be exposed to temperatures
near or below freezing, adequate measures must be taken
to prevent condensate from freezing. The use of
insulation and/or heat tape is recommended. Failure to
provide proper condensate drainage can result in property
damage.
SYSTEM OPERATION
15
B RRTG R JRR T R
T RRT R KTRT T
T
RRTKT
T B TR RR R RT
R T BRR BQ TR R R
G
gas at standard altitude. Propane gas installations require
High altitude installations may require both a pressure switch
compensate for the natural reduction in the density of both
the gas fuel and the combustion air at higher altitude.
Refer to the Accessories Charts in this manual or product
Specification Sheet for a tabular listing of appropriate
manufacturer’s kits for propane gas and/or high altitude
installations. The indicated kits must be used to insure
safe and proper furnace operation. All conversions must be
VENT/FLUE PIPE AND COMBUSTION AIR
PIPE ONLY)
RT T TRT RT B JRR
T
R R TRT G T
T
T T R TT R T T
TR T BT T T R TRT
RR K T T RT R
R JRR T TXRT RT
G RB X
by extracting almost all of the heat from the products of
combustion and cooling them to the point where condensation
and water condensation requirements, PVC pipe is used as
venting material.
This furnace must not be connected to Type B, BW, or L vent
or vent connector, and must not be vented into any portion
of a factory built or masonry chimney except when used as
a pathway for PVC as described later in this section.
common vent this appliance with another appliance or use a
vent which is used by a solid fuel appliance.
It is the responsibility of the installer to follow the manufacturers’
connectors are compatible with furnace flue products.
Additionally, it is the responsibility of the installer to ensure
that all piping and connections possess adequate structural
or sagging during furnace operation.
T B JR RR X T TT B
KT R GT R RK
X T T RBTB Q BRTG
T RR TT TK R
Precautions should be taken to prevent condensate from
exposed to temperatures below 35°F for extended periods
of time should be insulated with 1/2” thick closed cell foam.
terminations shown in this manual (or in unheated areas)
should be insulated with 1/2” thick closed cell foam. Inspect
piping for leaks prior to installing insulation.
The following bullets and diagram describe the restrictions
combustion air intake pipe (when applicable) terminations.
termination construction.
• All terminations must be located at least 12 inches above
ground level or the anticipated snow level.
• Vent terminations must terminate at least 3 feet above
any forced air inlet located within 10 feet.
• This provision does not apply to the combustion
air intake termination of a direct vent application.
• The vent termination of a non-direct vent application
must terminate at least 4 feet below, 4 feet horizontally
from, or 1 foot above any door, window, or gravity air
inlet into any building.
• The vent termination of a direct vent application must
terminate at least 12 inches from any opening through
or gravity air inlet).
• The vent termination of vent pipe run vertically through
a roof must terminate at least 12 inches above the roof
line (or the anticipated snow level) and be at least 12
inches from any vertical wall (including any anticipated
snow build up).
• A vent termination shall not terminate over public
walkways or over an area where condensate or
vapor could create a nuisance or hazard or could be
detrimental to the operation of regulators, relief valves,
or other equipment.
• The combustion air intake termination of a direct vent
application should not terminate in an area which is
frequently dusty or dirty.
In Canada, the B149 Fuel Gas Code takes precedence
over the preceding termination restrictions.
SYSTEM OPERATION
16
NON-DIRECT VENT
VENT/FLUE TERMINATION
NO TERMINATIONS
ABOVE WALKWAY
4'
4'
NON-DIRECT VENT
VENT/FLUE TERMINATION
DIRECT VENT
VENT/FLUE TERMINATION
FORCED AIR
INLET
OTHER THAN
COMBUSTION AIR
TERMINATION INTAKE
GRADE OR HIGHEST
ANTICIPATED
SNOW LEVEL
T RBBR B T G TRT T
RBBR B T XTR TT R BT
XTR RT BTK TQT RT
T G G RT KG B
JRR T TXRT G G RB
X
Refer to the following tables for applicable length, elbows, and
single 90° elbow must be secured to the combustion air intake
to prevent inadvertent blockage. The tee or elbows used in
the number of elbows in the piping system.
12345678
275 71 67 63 60 56 52 48
3126 120 115 110 105 99 94 89
237 33 30 26 22 18 15 11
3107 102 96 91 86 81 75 70
2100 95 90 85 80 75 70 65
3168 161 154 147 140 133 126 119
250 45 40 35 30 25 20 15
3143 136 129 122 115 108 101 94
260 55 50 45 40 35 30 25
3113 106 99 92 85 78 71 64
260 55 50 45 40 35 30 25
3120 113 106 99 92 85 78 71
245 40 35 30 25 20 15 10
3103 96 89 82 75 68 61 54
245 40 35 30 25 20 15 10
3151 144 137 130 123 116 109 102
*M EC961205DN 3185 178 171 164 157 150 143 136
2100 95 90 85 80 75 70 65
3110 103 96 89 82 75 68 61
245 40 35 30 25 20 15 10
3110 103 96 89 82 75 68 61
235 30 25 20 15 10 5NA
3103 96 89 82 75 68 61 54
245 40 35 30 25 20 15 10
3110 103 96 89 82 75 68 61
*CEC960603BN
*CEC960803BN
*CEC961005CN
2.5" pipe may be used instead of 2" pipe.
For installations at or above 7,000 altitude use 3" venting (and combustion
*M EC960603BN^
*M EC960803BN
*M EC960804CN
*M EC961004CN
*M EC961005CN
*CEC960403BN
*M EC96/*CEC96 Direct Vent (2 - Pipe) and Non-Direct V ent (1- Pipe) (6)
Maximum Allowable Length of Vent/Flue Pipe
M ODE L
Pipe Size
(4) (in.)
Number of Elbows (3) (5)
*M EC960302BN
&
*M EC960402BN
*M EC960303AN
&
*M EC960403AN
*M EC960603AN^
in the piping system.
4) 2 1/2” or 3” diameter pipe can be used in place of 2” diameter pipe.
equivalent to one 90 deg. elbow.
6) One 90° elbow should be secured to the combustion air intake connection.
SYSTEM OPERATION
17
X
R
12” MIN
HEIGHT DIFFERENCE
BETWEEN
INTAKE AND VENT
12” MIN TO ROOF OR HIGHEST
ANTICIPATED SNOW LEVEL
STRAIGHT
ELBOWS
90˚
ELBOWS
12"M IN.A BOVE
HIGH ESTA NTICIPATED
SNOW LEVE L
3”-24” BETWEENP IPES
Combustion Air Intake may also be snorkeled to obtain 12” min groun d
clearance.
AlternateVentTerminationAboveAnticipatedSnowLevel
(DualPipe)
If more than one direct vent furnace is to be installed
vertically through a common roof top, maintain the same
minimum clearances between the exhaust vent and air intake
terminations of adjacent units as with the exhaust vent and
air intake terminations of a single unit.
If more than one direct vent furnace is to be installed
horizontally through a common side wall, maintain the
exhaust vent outlets at the same elevation and always
terminate all air intakes at the same elevation.
SYSTEM OPERATION
18
3” MIN
12” MIN TO GRADE OR HIGHEST
ANTICIPATED SNOW LEVEL
12” M IN SEPA RATION
3”MIN
24”MAX
Direct Vent
Terminal
50,000 Btuh
or less
9"
12"
12" 12"
Direct Vent Terminal
More than 50,000 Btuh
Forced Air Inlet
3'
1. The vent termination must be located at least 12” above
ground or normally expected snow accumulation levels.
2. Do NOT terminate over public walkways. Avoid areas
where condensate may cause problems such as above
planters, patios, or adjacent to windows where steam
may cause fogging.
3. The vent termination shall be located at least 4’
horizontally from any electric meter, gas meter, regulator
and any relief equipment. These distances apply ONLY
to U.S. Installations.
4. The vent termination shall be located at least 3’ above
any forced air inlet located within 10’; and at least 10’
from a combustion air intake of another appliance, except
another direct vent furnace intake.
5. In Canada, the Canadian Fuel Gas Code takes
precedence over the preceding termination instructions.
3" or 4" Diameter
SDR-26 Pipe
2 or 2 1/2" Diameter
SDR-26 Pipe
2" or 3" Diameter
Y Concentric Fitting
2" or 3" Diameter
Rain Cap
These kits are for vertical or horizontal termination of the
combustion air inlet and the exhaust vent pipes on Category
kit can be used for 3” diameter pipe systems. The DCVK-
20 (CVENT-2) kit can be used for the 2” diameter pipe
system. Both the combustion air inlet and the exhaust vent
pipes must attach to the termination kit. The termination kit
must terminate outside the structure and must be installed
per the instructions outlined below for vertical or horizontal
termination. Vertical termination is preferred. Field supplied
1. Determine the best location for the termination kit. Roof
termination is preferred since it is less susceptible to dam-
age, has reduced intake contaminants and less visible
vent vapors. For side termination, consideration should
be given to:
a. Possible damage from the vapors to plants/shurbs,
other equipment and building materials
b. Possible damage to the terminal from foreign objects
products, debris or light snow
d. Visible vent vapors.
SYSTEM OPERATION
19
Maintain 12" (18" for Canada)
minimum clearance above highest
anticipated snow level. Maximum of
24" above roof.
Combustion Air
Roof Boot/Flashing
(Field Supplied)
Support (Field Supplied)
45 Elbow
(Field Supplied)
Combustion Air
Vent
by extracting almost all of the heat from the products of
combustion and cooling them to the point where condensation
takes place. The condensate which is generated must be
piped to an appropriate drain location.
RGT TT T R TR T BT
T T T T R T JT BX
T
R T RK TR RG T JT BX T T
BK R T
RT T TRT
RT B RRTG R JR R T
TTR K
• •If the drain line is routed through an area which may
see temperatures near or below freezing, precautions
must be taken to prevent condensate from freezing
within the drain line.
• •If an air conditioning coil is installed with the furnace,
a common drain may be used. An open tee must
be installed in the drain line, near the cooling coil, to
relieve positive air pressure from the coil’s plenum.
This is necessary to prohibit any interference with the
function of the furnace’s drain trap.
The furnace rating plate includes the approved furnace gas
input rating and gas types. The furnace must be equipped
to operate on the type of gas applied. This includes any
conversion kits required for alternate fuels and/or high altitude.
T
RT RB RT R QT G T T
G RRT B T T RTG T
T TR G R RTG
Inlet gas supply pressures must be maintained within the
operating. The minimum gas supply pressure must be
maintained to prevent unreliable ignition. The maximum must
Natural Gas Minimum: 4.5" w.c. Maximum: 10.0" w.c.
Propane Gas Minimum: 11.0" w.c. Maximum: 13.0" w.c.
When this furnace is installed at high altitude, the appropriate
to the natural reduction in the density of both the gas fuel and
combustion air as altitude increases. The kit will provide the
range.
High altitude kits are purchased according to the installation
altitude and usage of either natural or propane gas. Refer
appropriate altitude ranges and corresponding manufacturer’s
high altitude (Natural, Propane gas, and/or Pressure Switch)
kits.
Do derate the furnace by adjusting the manifold pressure
The combination of the lower air density and a lower manifold
amount of air into the burner. This may cause incomplete
determined based upon the BTU/ft3content of the derated
gas and the altitude. Refer to the National Fuel Gas Code,
NFPA 54/ANSI Z223.1, and information provided by the gas
regardless of the BTU/ft3content of the fuel used. Refer to the
altitude ranges and corresponding manufacturer’s pressure
switch kits.
SYSTEM OPERATION
20
B RRTG R JRR T R
T RRT R KTRT T T RRTKT
T B TR RR R RT
R T BRR BQ TR R R
G
This unit is configured for natural gas. The appropriate
manufacturer’s propane gas conversion kit, must be applied
for propane gas installations.
Refer to the specification sheet for the model you are
servicing. Refer to the “propane gas and/or High Altitude
Installations” section for details.
This unit is equipped with a 24 volt gas valve controlled
during furnace operation by the integrated control module.
appropriate propane gas conversion kit. Taps for measuring
the gas supply pressure and manifold pressure are provided
on the valve.
NOTE: The gas supply pressure on White-Rodgers “G/J”
model gas valve, can be checked with a gas pressure test
kit (Part #0151K00000S) available through our authorized
distributors.
The gas valve has a manual ON/OFF control located on
the valve itself. This control may be set only to the “ON” or
“OFF” position. Refer to the Lighting Instructions Label or the
“Putting the Furnace Into Operation” section of this manual or
the installation instructions for use of this control during start
up and shut down periods.
T B TTRRT R QT G
TRRG QT T RR
TRR G G RG R T
TRTK TT R
The gas piping supplying the furnace must be properly sized
and length of the run. The gas line installation must comply
with local codes, or in their absence, with the latest edition of
the National Fuel Gas Code, NFPA 54/ANSI Z223.1.
Length of Nominal Black Pipe Size
Pipe in Feet 1/2" 3/4" 1" 1 1/4" 1 1/2"
132 278 520 1050 1600
92 190 350 730 1100
73 152 285 590 980
63 130 245 500 760
56 115 215 440 670
50 105 195 400 610
46 96 180 370 560
43 90 170 350 530
40 84 160 320 490
38 79 150 305 460
CFH =
(Pressure 0.5 psig or less and pressure drop of 0.3" W.C.; Based on 0.60 Specific
Gravity Gas)
BTUH Furnace Input
Heating Value of Gas (BTU/Cubic Foot)
To connect the furnace to the building’s gas piping, the installer
cases, the installer may also need to supply a transition piece
from 1/2” pipe to a larger pipe size.
The following stipulations apply when connecting gas piping.
to the furnace.
piping.
2. Use pipe joint compound on male threads only. Pipe
joint compound must be resistant to the action of the
fuel used.
3. Use ground joint unions.
4. Install a drip leg to trap dirt and moisture before it can
enter the gas valve. The drip leg must be a minimum of
three inches long.
gage connection, immediately upstream of the gas
supply connection to the furnace.
6. Use two pipe wrenches when making connection to
the gas valve to keep it from turning. The orientation of
the gas valve on the manifold must be maintained as
shipped from the factory.
and unit within six feet of the unit. If a union is installed,
8. Tighten all joints securely.
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